Laundry machine drive

ABSTRACT

A drive for a laundry machine having a means for agitating water and fabrics to launder the fabrics and for spinning the fabrics to effect centrifugal displacement of water from the fabrics. An electronically commutated motor energized from a DC power source for driving the agitating and spinning means includes a stator with a plurality of winding stages adapted to be electronically commutated in a plurality of preselected sequences, and a rotatable assembly is arranged in selective magnetic coupling relation with the winding stages so as to be rotatably driven thereby. The rotatable assembly is rotatably driven in one direction in response to the electronic commutation of at least some of the winding stages in one of the preselected sequences and also in the one direction and another direction opposite thereto in response to the electronic commutation of the winding stages in another of the preselected sequences. Means is provided for driving the agitating and spinning means from the rotatable assembly of the electronically commutated motor.

This is a divisional, of application Ser. No. 487,921, filed Apr. 22,1983, which in turn was a division of Ser. No. 304,536, filed Sept. 22,1981 (now U.S. Pat. No. 4,434,546 issued Mar. 6, 1984), which was adivision of Ser. No. 077,784 filed Sept. 21, 1979 (now U.S. Pat. No.4,327,302 issued Apr. 27, 1982).

FIELD OF THE INVENTION

This invention relates in general to laundry apparatus.

BACKGROUND OF THE INVENTION

In the past conventional DC motors, commutation was effected by brushesriding on a segmented commutator so as to control the currents flowingthrough the armature winding sections of such past conventional DCmotors. Of course, one of the disadvantageous or undesirable featuresattendent to the above discussed commutated DC motors is believed to bethat wear of the brushes thereof necessitated frequent brushreplacement. Other disadvantageous features of these past commutated DCmotors are belived to be that sparking may have occurred between thebrushes and segmented commutator thereof which not only may haveeffected RF interference but also may have limited the use of suchcommutated DC motors in some critical or particular environmentalapplications.

Various circuit and motor design schemes have been utilized in the pastto develop various types of brushless DC motors, and one such scheme isshown in the David M. Erdman U.S. Pat. No. 4,005,347 issued Jan. 25,1977 and U.S. Pat. No. 4,015,182 issued Mar. 29, 1977, each of which areincorporated herein by reference. In these patents, a brushless DC motorhas a stator with a plurality of windings therein, a rotor having aplurality of constant magnetic polar regions, and means for sensing therelative position of the rotor polar regions with respect to the stator.Positive signals developed by the position sensing means were processedby circuitry for selectively energizing the windings of the motor.

In the present day clothes washing or laundry machines having agenerally coaxially arranged agitator and a spin tub, the agitator isrotated with an oscillating movement, and the rotation of the spin tubis unidirectional at a speed appreciably greater than that of theagitator oscillation. Of course, many different transmission mechanismand drive schemes have been employed inthe past to effect theaforementioned particular oscillation and unidirectional rotation of theagitator and spin tub; however, it is believed that a disadvantageous orundesirable feature of such past schemes was that they were too costlyand/or too complicated not only from the viewpoint of manufacture butalso from the viewpoint of power usage and maintenance by the consumer.

SUMMARY OF THE INVENTION

Among the several objects of the invention may be noted the provision ofan improved drive for a laundry machine and which overcomes the abovediscussed disadvantageous or undesirable features, as well as others, ofthe prior art; the provision of such improved drive utilizes anelectronically commutated motor having stationary and rotatableassemblies which are of a compact size and yet provide a comparativelylarge output rating;

the precision of such improved drive in which the inertia of the movingparts thereof is low;

the provision of such improved drive in which a transmission mechanismis selectively operable to directly drive an agitator and a spin tub ofthe laundry machine and wherein such transmission is directly driven bythe electronically commutated motor; and the provision of such improveddrive which is simplistic in design, easily assembled and economicallymanufactured. These as well as other objects and advantageous featuresof the present invention will be in part apparent and in part pointedout hereinafter.

In general and in one form of the invention, a drive is provided for alaundry machine having a DC power source associated therewith and alsohaving a means for agitating water and fabrics to be laundered therebyand for thereafter spinning the fabrics to effect centrifugaldisplacement of water from the fabrics. The drive has an electronicallycommutated motor adapted to be energized from the DC power source fordriving the agitating and spinning means, and the electronicallycommutated motor includes a stator having a multi-stage windingarrangement with a plurality of winding stages adapted to beelectronically commutated in a plurality of preselected sequences. Arotatable assembly associated with the stator is arranged in selectivemagnetic coupling relation with the winding stages so as to be rotatablydriven thereby, and the rotatable assembly is rotatably driven in onedirection in response to the electronic commutation of at least some ofthe winding stages in one of the preselected sequences and also isrotatably driven in the one direction and another direction oppositethereto in response to the electronic commutation of the winding stagesin another of the preselected sequences. Means is provided for drivingthe agitating and spinning means from the rotatable assembly of theelectronically commutated motor.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is an enlarged plan view of a punched out rotatable assemblylamination;

FIG. 2 is a functional box diagram illustrating a method of making acore for use in a rotatable assembly of a dynamoelectric machine;

FIGS. 3-8 are enlarged partial views of the lamination of FIG. 1 andillustrate principles which may be practiced in the method representedby the functional box diagram of FIG. 2;

FIG. 9 is an end view of a rotatable assembly which may be formed inaccordance with the method illustrated by the functional box diagram ofFIG. 2;

FIG. 10 is a sectional view taken along line 10--10 of FIG. 9.

FIG. 11 is a sectional view taken along line 11--11 of FIG. 10;

FIG. 12 is a graphical representation illustrating the magneticproperties of magnetic material elements utilized in the rotatableassembly of FIGS. 9-11 as well as those of other magnetic materialelements.

FIG. 13 is a greatly enlarged end view illustrating a stationaryassembly with a plurality of winding stages schematically shown andarranged in the stationary assembly; FIG. 14 is a partial sectional viewtaken from FIG. 13 illustrating the disposition of coils of the windingstages with a coil receiving slot of the stationary assembly;

FIG. 15 is a schematic diagram illustrating the distribution of thewinding stages in the coil receiving slots of the stationary assembly inFIG. 13;

FIGS. 15A and 15B are schematic diagrams illustrating the distributionof alternative winding stages as they may be arranged in the coilreceiving slots of the stationary assembly of FIG. 3, respective

FIG. 16 is an actual size plan view illustrating an electronicallycommutated motor;

FIG. 17 is an end view of the electronically commutated motor of FIG.16;

FIG. 18 is a sectional view taken along line 18--18 of FIG. 17;

FIG. 19 is a diagrammatic representation illustrating positions of polesections in the rotatable assembly of the electronically commutatedmotor of FIGS. 16-18 with respect to the winding stages in thestationary assembly thereof at the instant one of the winding stages iscommutated so as to be excited;

FIG. 20 is a graphical representation of the voltage which may bedeveloped upon the selective energization of the winding stages in theelectronically commutated motor of FIGS. 15-19;

FIG. 21 is a sectional view illustrating a transmission mechanismadapted for use in a laundry machine;

FIGS. 22-24 are sectional views taken along lines 22--22, 23--23 and24--24 in FIG. 21, respectively;

FIG. 25 is a partial sectional view illustrating a laundry machine aswell as a drive therefor in one form of the invention;

FIG. 26 is an enlarged partial view partially in cross-section takenfrom FIG. 25;

FIGS. 27 and 28 are partial sectional views illustrating alternativepole sections which may be utilized in the lamination of FIG. l,therotatable assembly of FIGS. 9-11 and the method of making such in FIGS.2-8 respectively;

FIG. 29 is an elevational view partially in section illustrating analternative rotatable assembly which may be utilized with the stationaryassembly in the electronically commutated motor of FIGS. 15-19;

FIG. 30 is a sectional view taken along lines 30--30 in FIG. 29;

FIG. 31 is a functional box diagram illustrating a method of making acore for use in the rotatable assembly of FIG. 29; and

FIGS. 32 and 33 are enlarged partial views of the core of FIGS. 29 and30 and illustrate principles which may be practiced in the methodrepresented by the functional box diagram of FIG. 31.

Corresponding reference characters refer to corresponding partsthroughout the several views of the drawings.

The exemplifications set out herein illustrate the preferred embodimentsof the invention in one form thereof, and such exemplifications are notto be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in general, there is shown at 41 alamination adapted to be used in a ferromagnetic core or rotor 43 of adynamoelectric machine, such as an electronically commutated motor orbrushless DC motor 45 or the like for instance (FIGS. 1, 9-11 and16-18). Lamination 41 has a unitary body 47 blanked or otherwise formedfrom a generally thin ferromagnetic material, such as an electricalgrade sheet steel or the like for instance, and a plurality of polesections 49 are spaced apart from each other generally about the body(FIG. 1). A plurality of means, such as inner peripheral bridges orconnecting arms 51 for instance, on body 47 are interposed betweenadjacent ones of pole sections 49 for bridging therebetween,respectively. A plurality of other pole sections 53 of body 47 areinterposed in spaced relation between the adjacent ones of pole sections49, and a plurality of sets or pairs of other means, such as outerperipheral bridges or connecting arms 55 or the like for instance, areinterposed between the adjacent ones of pole sections 49 and polesections 53 for bridging therebetween, respectively.

More particularly and with specific reference to FIG. 1, body 47 oflamination 41 has a pair of radially spaced outer and inner peripheraledges 57, 59 with the inner peripheral edge defining a generallycentrally located shaft receiving bore or the like through the body asdiscussed hereinafter. A plurality of openings, such as generallyV-shaped apertures or slots 61 for instance, are provided through body47 between peripheral edges 57,59 thereof,respectively, and the openingsare arranged with each other in generally arcuate spaced relation aboutthe body. Thus, pole sections 49 respectively are defined on body 47generally between adjacent ones of openings 61.

Each of openings 61 has a pair of leg parts 63,65 tapering toward eachother generally in a direction from outer peripheral edge 57 towardinner peripheral edge 59. Leg parts 63,65 each have a pair of oppositeside edges 67,69 and 71, 73, and a pair of end edges or end portions75,77 are interposed between the side edges generally adjacent outerperipheral edge 57 while a common end edge or end portion 79 isinterposed between side edges 67,73 generally adjacent inner peripheraledge 59. Thus, side edges 67,73 of leg parts 63,65 are provided onadjacent ones of pole sections 49, and side edges 69,71 are provided onpole sections 53 between the adjacent ones of pole sections 49,respectively. Further, bridging means or inner bridges 51 are definedbetween inner peripheral edge 59 and common end edge 79 so as tointegrally interconnect between pole sections 49, and sets or pairs ofbridging means or outer bridges 55 are arranged between outer peripheraledge 57 and each end edge 75,77 of leg parts 63,65 in openings 61 so asto define narrow peripheral bands or strips on body 47 which may bedeformed generally radially inwardly toward the leg parts, respectively,as discussed in detail hereinafter. Thus, bridges or bridge pairs 55 areintegrally interconnected between each pole section 53 and the polesections 49 adjacent thereto, respectively. Pole sections 53 are definedgenerally between side edges 69, 71 of leg parts 63,65 in openings 61and extend therebetween generally radially inwardly from outerperipheral edge 57 toward inner peripheral edge 59. The radially innerends of side edges 69,71 intersect with a free end edge 81 on polesection 53 which is arranged generally in opposite or facing relationwith common end edge 79, and a pair of opposite tabs or abutments 83,85integrally formed on each of pole sections 53 extend generally from theopposite side edges of the pole section at least generally adjacent thefree end edge into leg parts 63,65 of openings 61, respectively. Whileopenings 61 are described herein as being generally V-shaped inlamination 41, it is contemplated that other openings having differentshapes may be employed within the scope of the invention so as to meetthe objects thereof, and of course, such different shaped cpenings wouldalso alter the shape of the pole sections.

Referring again in general to the drawings and recapitulating at leastin part with respect to the foregoing, there is illustrated a method formaking, manufacturing or assembling rotor 43 which has a plurality ofdiscrete polar regions or areas, such as generally defined by polesections 49,53, with such polar regions or pole sections being spacedapart generally about a peripheral portion 87 of the rotor (FIGS. 3-10).In this method, pole sections 53 are positioned, disposed or otherwiselocated or arranged in preselected positions spaced between adjacentones of pole sections 49 (FIGS. 1 and 3), and a plurality of sets orpairs of magnetic material elements 89,91 are disposed or otherwisearranged between pole sections 53 and the adjacent ones of pole sections49, respectively (FIGS. 4 and 5). A hardenable nonmagnetic material 93is provided in rotor 43 between pole sections 49,53 and magneticmaterial elements 89,91, so as to be solidified in place therebetween,and the nonmagentic material acts along with the magnetic materialelements to effect magnetic polarity definition between pole sections49,53 while also retaining or maintaining the magnetic material elementsand pole sections 53 in their preselected positions againstdisplacement, respectively (FIG. 6). Hardenable material 93 may bealuminum, copper or respective alloys thereof or other nonmagneticmaterials having good electrical conductivity properties.

More particularly and with specific reference to FIGS. 1-8 and 10, aplurality of laminations 41 are stacked or otherwise assembled togethergenerally in juxtaposed or face-to-face relation, as illustratedgenerally in FIGS. 3 and 10, thereby to form a lamination stack 95having a predetermined stack height or length required for rotor 43 ofFIG. 10, and the stacking of the laminations is illustrated byfunctional diagram box 97 in FIG. 2. Either during or subsequent to theabove discussed stacking of laminations 41 into rotor stack 95, openings61 of the lamination are respectively aligned or otherwise arranged witheach other so as to define a plurality of slots or slot openings 99which extend through rotor 43 between a pair of opposite ends or endportions 101, 103 thereof, as best seen in FIGS. 3 and 10. Even thoughthe alignment of openings 61 so as to form slots 99 may be accomplishedduring the stacking of laminations 41, as discussed above, such openingalignment is illustrated in a separate functional diagram box 105 ofFIG. 2. Although slots 99 are shown as extending generally axiallythrough rotor 43 between opposite ends 101, 103 thereof, it iscontemplated that the slots may be slightly skewed during the alignmentof openings 61 within the scope of the invention so as to meet at leastsome of the objects thereof. Further and albeit not shown for the sakeof brevity, it is to be understood that suitable equipment may beemployed to effect the stacking of laminations 41 and the alignment ofopenings 61 so as to form slots 99 through stator 43. Of course, it mayalso be noted that upon the above discussed alignment of openings 61,outer and inner peripheral edges 57, 59 of laminations 41 in stack 95thereof are also generally aligned or otherwise arranged with each otherso that outer peripheral edges 57 generally define peripheral portion orwall 87 on rotor 43 between opposite ends 101, 103 thereof and innerperipherial edges 59 generally define a shaft receiving bore 107extending through the rotor between the opposite ends thereof,respectively, as best seen in FIG. 10. Of course, the particular edgeson laminations 41 which define openings 61 therethrough, as discussedhereinabove, are also disposed generally in alignment with each otherupon the alignment of the openings so as to form slots 99 in rotor stack95, and such particular edges in their aligned formation define wall orwall means of the slot; however, for the sake of brevity, such slotwalls will be designated by the reference numeral of such particularedges corresponding thereto when referred to hereinafter.

Magnetic material elements 89,91, such as elongate block or bar magnetsfor instance, are provided with a pair of opposite generally flatsurfaces or faces 109, 111 interposed between a pair of oppositegenerally flat intermediate surfaces or end faces 113, 115,respectively. When openings 61 of laminations 41 are aligned throughrotor.stack 95 to define slots 99 thereof,as discussed above, magnets89,91 are respectively inserted, placed, positioned or otherwisedisposed within of the slots so that opposite faces 109,111 of themagnets are arranged generally in facing relation with oppositesidewalls 67,69 and 71, 73 of the slots extending through rotor stack95, respectively, as shown in FIG. 4. In other words, opposite faces109, 111 of magnets 89,91 extend generally in face-to-face relation withpole sections 49,53 generally throughout their lengths with respect toslots 99 between opposite end faces 101, 103 of rotor stack 95. Ofcourse, due to manufacturing tolerances for both lamination 43 andmagnets 89, 91, it is contemplated that the magnets may be generallyloosely positioned in slots 99. Upon the placement of magnets 89,91within slots 99, opposite intermediate surfaces 115 of the magnets maybe seated or otherwise located on opposite tabs 83,85 of pole sections53 so that the other opposite intermediate surace 113 of the magnets arespaced from outer bridges or bridge sections 55 in rotor stack 95.Magnets 89,91 are available from TDK Electronics Co.. Ltd., 2-14-6,Uchikanda, Chiyoda-ku, Tokyo, Japan under Model No. TDK-30 and generallyhave the magnetic characteristics as illustrated in the graph of FIG.12. The placement of magnets 89,91 in slots 99 is illustrated infunctional diagram box 117 in FIG. 2. While the particular shape andmagnetic characteristics of magnets 89,91 are disclosed herein, it iscontemplated that other magnets having other shapes and/or othermagnetic characteristics may be employed in rotor 43 within the scope ofthe invention so as to meet the objects thereof, and it is alsocontemplated that more than two magnets may be utilized in thedefinition of a polar region of the rotor within the scope of theinvention so as to meet the objects thereof. For the sake of comparison,the magnetic characteristics of some of the above mentioned othermagnets which might be employed in rotor 43 are also shown in the graphof FIG. 12.

After the placement of magnets 89,91 within slots 99 of rotor stack 95,outer bridges 55 of laminations 41 are displaced or otherwise deformedgenerally along the entire length of the rotor stack between 5 oppositeends 101, 103 thereof in a direction generally inwardly of the corestack or toward leg parts 63,65 of the slots, as shown in FIG. 5.Bridges 55 in rotor stack 95 may be so deformed by a tool 119, asillustrated schematically in FIG. 5, forced against outer peripheralportion 87 of rotor 43 generally along the bridges. In response to thisdeformation of outer bridges 55, pole sections 53 and magnets 89,91 aremovable therewith and relative to pole sections 49 so that oppositefaces 109, 111 of the magnets are abutted or otherwise engaged generallyin face-to-face relation with pole sections 49 and pole sections 53,respectively. Of course, this deformation of outer bridges 55 and theresulting movement of pole sections 53 and magnets 89,91 is just greatenough to take up the aforementioned manufacturing tolerancestherebetween to insure that opposite faces 109,111 of the magnets areengaged in the face-to-face relation with pole sections 49,53 generallyalong the lengths thereof in slots 99. However, if the aforementionedmanufacturing tolerances between magnets 89,91 and pole sections 49,53are satisfactory so as to afford an acceptable or desirable fluxtransfer relation therebetween, it is contemplated that the abovediscussed deformation of bridges 55, as illustrated in functionaldiagram box 121, of FIG.2, may be omitted from the method ofmanufacturing rotor 43 within the scope of the invention so as to meetthe objects thereof. Albeit not shown for the purpose of disclosurebrevity, it is understood that suitable equipment may be utilized toeffect the deformation of outer bridges 55 generally simultaneously orin any given order so as to effect the tolerance take-up movement ofpole sections 53 and magnets 89,91, as discussed above.

With magnets 89,91 so respectively positioned within slots 99 inabutment between pole sections 49, 53, a squirrel cage winding,indicated generally at in FIGS. 9 and 10, is integrally formed withrotor stack 95, and the squirrel cage winding comprises a pluraltiy ofrotor bars 125 extending through the slots and integral with a pair ofopposite generally annular end rings 127, 129 disposed on opposite ends101, 103 of the core stack between peripheral portion 87 and bore 107thereof, respectively. If desired, a plurality of fan blades 131 mayalso be integrally formed with end rings 127, 129, respectively. Ofcourse, it i.s contemplated that suitable equipment may be employed toeffect the formation of squirrel cage winding 123 with rotor stack 95;however, for the sake of brevity, a disclosure of such equipment isomitted. In the formation of squirrel cage winding 123, hardenablematerial 93 is provided or otherwise introduced into the intersticeswithin slots 99 generally about magnets 89,91 therein and between polesections 49, 53 and inner and outer bridges 55,59, respectively, asshown in FIG. 6. Thus, hardenable materials 93 fills the aforementionedinterstices within slots 99 throughout the lengths thereof betweenopposite ends 101, 103 of rotor stack 95, so as to define bars 125therein, and generally simultaneously therewith, opposite end rings 127,129 of the hardenable material are formed or otherwise defined onopposite ends 101, 103 of the rotor stack, respectively. Of course,hardenable material 93 may be poured, cast, injected or otherwiseprovided in slots 99 of rotor stack 95 so as to effect the generallysimultaneous formation of bars 125 and opposite end rings 127, 129 ofsquirrel cage winding 123 with the rotor stack upon the solidificationin place of the hardenable material. The formation of squirrel cagewinding 123 is illustrated generally by a functional diagram box 133 inFIG. 2.

When hardenable material 93 is solidified in situ so as to form squirrelcage winding 123 on rotor stack 95, as discussed above, a part of eachdeformed outer bridge 55 may be removed from peripheral portion 87 ofthe core stack so as to provide a plurality of grooves or spaces 135between pole sections 49, 53 disjoining or otherwise disassociating themalong the entire length of the core stack between opposite ends 101, 103thereof, respectively, as shown in FIG. 7 and illustrated by afunctional diagram box 137 in FIG. 2 To effect this aforementioneddisjoinder of pole sections 49, 53, a tool, such as a milling orbroaching tool or the like for instance as schematically illustrated at139 in FIG. 7, may be engaged with deformed outer bridges 55 onperipheral portion 87 of rotor stack 95 and operated to machine awayportions or sections of the bridges along the entire length of the corestack between opposite ends 101, 103 thereof so as to effect thephysical separation or disjoinder of pole sections 49, 53. However, itshould be noted that upon the above described disjoinder of polesections 49, 53, grooves 135 are located or otherwise arranged betweenthe pole sections so that remaining parts or sections of deformedbridges 45 define a pair of opposed flanges or extensions 141, 143 onadjacent ones of pole sections 49 which extend therefrom in part overleg parts 63,65 of slots 99 along the length of rotor stack 95 betwenopposite ends 101, 103 thereof, respectively. It is, of course,contemplated that deformed outer bridges 55 may be machined generallysimultaneously or in any selected order within the scope of theinvention so as to meet at least some of the objects thereof. Also, itis contemplated that suitable equipment may be utilized to effect themachining of deformed outer bridges 55, but for the sake of brevity, adisclosure of such equipment is omitted.

Upon the above discussed disjoinder of pole sections 49, 53, it may benoted that portions of hardenable material 93 are predeterminatelysolidified in place or otherwise arranged between the pole sectionswithin slots 99 so as to be abutted or otherwise engaged between opposedflanges 141, 143 on pole sections 49 and opposite surfaces113 of magnets89, 91. Since opposite surfaces 115 of magnets 89,91 are seated onopposite tabs 83,85 of pole sections 53, the coaction of the magnets andthe aforementioned portions of hardenable material 93 engaged betweenflanges 141, 143 and opposite surfaces 113 of the magnets serve to cageor otherwise retain or maintain pole sections 53 against displacementfrom slots 99, respectively. Further, it may also be noted that thedisposition of hardenable material 93 and magnets 89, 91 within slots 99in abutment between pole sections 49,53 also serve to effect themagnetic polarity definition between the pole sections. In other words,hardenable material 93 and magnets 89,91 in their respective abutting orspacing relation between pole sections 49,53 effectively magneticallydefine the polarity of pole sections 53 from that of adjacent ones ofpole sections 49 which are integrally interconnected with each other byinner bridges 59. Thus, in response to the magnetic affect of magnets89,91, pole sections 53 are each magnetized so as to have the samepolarity while pole sections 49, which are integrally interconnected byinner bridges 59, each are magnetized so as to have a polarity oppositeto that of pole sections 53. In view of the foregoing, it may be furthernoted that pole sections 49,53 define discrete constant polar regions orareas extending generally about peripheral portion 87 of rotor 43 andbetween opposite ends 101, 103 thereof, respectively.

Subsequent to the disjoinder of pole sections 49, 53 in rotor stack 95,peripheral portion 87 thereof may be turned or otherwise machined toprovide the rotor stack with a preselected diameter. As seen in FIG. 8and as illustrated by a functional diagram box 145 in FIG. 2, outerperipheral edges 57 of laminations 41 in rotor stack 95 may be engagedand machined by a tool, such as a lathe bit or the like for instanceillustrated schematically at 147 in FIG. 8, thereby to provideperipheral portion 87 of the rotor stack with a preselected outsidediameter generally between opposite ends 101, 103 thereof. While theabove discussed turning of rotor stack 95 to the preselected outsidediameter thereof may be performed by certain equipment, such as a latheor the like for instance, a disclosure of such equipment is omitted forthe sake of brevity.

With respect to the magnetization of magnets 89,91, it is preferred thatsuch magnetization be accomplished upon the assembly of electronicallycommutated motor 45, as discussed hereinafter. In other words, onceelectronically commutated motor 45 is assembled together, pole sections49,53 of rotor 43 may be aligned under a particular one of the windingstages of the electronically commutated motors, and when so aligned, arelatively high current may be passed through such particular onewinding stage thereby to effect the magnetization of magnets 89,91, aswell known in the art. Of course, it is contemplated that suitableequipment may be utilized to effect the magnetization of magnets 89,91in rotor 43, as discussed above, but for the sake of brevity, adescription of such suitable equipment is omitted. While themagnetization of magnets 89,91 in rotor 43 as discussed above ispreferred, it is also contemplated that the magnets could be magnetizedbefore they are disposed in rotor slots 99 or subsequent to thecompletion of the assembly of rotor 43 by magnetizing pole sections49,53 thereof all at the same time within the scope of the invention soas to meet at least some of the objects thereof.

Referring again in general to the drawings and recapitulating at leastin part with respect to the foregoing, there is shown a rotatableassembly 151 which is adapted to be used in dynamoelectric machine 45(FIGS. 9-11 and 8). Rotatable assembly 151 comprises rotor 43 having aplurality of means, such as slots 99 which may be thought of asincluding grooves 135 for receiving pole sections 53 in the rotor (FIGS.10 and 11). Means, indicated generally at 153, is provided in receivingmeans or slots 99 for defining the the magnetic polarity of polesections 53 with respect to adjacent parts of rotor 43, such as forinstance the ones of pole sections 49 of the rotor adjacent polesections 53, and for retaining or maintaining pole sections 53 againstdisplacement from the slots, respectively (FIGS. 10 and 11). Definingand retaining means 153 include magnets 89,91 disposed between polesections 49,53 and hardenable material 93 solidified in place in slots99 between pole sections 9,53 and the magnets, respectively (FIGS. 10and 11).

More particularly and with specific reference to FIGS. 9-11, rotor 43has its shaft receiving bore 107 defined therein by inner peripheraledges 59 of laminations 41 in rotor stack 95, and the bore intersectswith opposite ends 101, 103 of rotor 43, respectively, as previouslymentioned. A shaft 155 is disposed in bore 107 in displacementpreventing engagement with rotor 43, and a pair of opposite extensionsor end sections 157,159 on the shaft extend generally axially beyondopposite ends 101, 103 of rotor 43, the shaft extensions being adaptedto be suitably journaled in dynamoelectric machine 45, as discussedhereinafter. Rotor 43 and shaft 155 may be assembled together in thedisplacement preventing engagement by suitable means, such aspress-fitting or heat shrinking for instance. In the preferredembodiment of rotatable assembly 151, rotor 43 is heated to effectexpansion of bore 107 therein, and at least one of the rotor and shaft155 are moved with respect to the other thereof in order to position thebore in a preselected coaxial location about the shaft with respect toat least one of opposite extensions 157, 159 thereof. When so located,rotor 43 is allowed to cool thereby to effect the contraction or heatshrinking of the rotor and its bore 107 into the displacement preventingor gripping engagement with shaft 155 in the preselected coaxiallocation thereon. While rotatable assembly 151 is disclosed having eightpoles, it is contemplated that other rotatable assemblies havingdifferent numbers of poles may be utilized within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again in general to the drawings, a stationary assembly161 shown is adapted to be used in electronically commutated motor 45(FIGS. 13-18). Stationary assembly 161 comprises a ferromagnetic core orstator 163 with a plurality of winding receiving slots 165 disposedgenerally thereabout (FIGS. 13 and 14). A multi-stage windingarrangement, indicated generally at 167, includes a plurality of windingstages 171, 173, 175 each having a plurality of coils 177-1 to 177-8,179-1 to 179-8 and 181-1 to 181-8 with each of the coils thereof havingat least one conductor turn 183 with opposite side portions 185 receivedor otherwise accommodated in respective ones of slots 165, respectively(FIGS. 13 and 15). Most, or at least some, of coils 177, 179, 181 inwinding stages 171, 173, 175 have a side turn portion 185 thereofsharing a respective one of slots 165 with a side turn portion of othercoils in the same winding stage, respectively (FIGS. 13 and 15). Twopairs of coils 179 in winding stage 173 have a side turn portion 185thereof sharing respective ones of slots 165 with two pairs of coils177, 181 in winding stages 171, 175, and two pairs of coils 167, 181 ofwinding stages 171, 175 have a side turn portion thereof which do notshare a respective one of slots 165, respectively (FIGS. 13 and 15).

More particularly and with specific reference to FIGS. 13-15, and 18,stator 163 has a generally cylindric shaped peripheral portion orsection 187 interposed or interconnected between a pair of opposite endfaces or portions 189, 191 of the stator; however, it is contemplatedthat other stators having various other shapes,such as oppositeperipheral flats thereon for instance as well as other slot shapes orconfigurations,may be utilized within the scope of the invention so asto meet at least some of the objects thereof. A plurality of teeth 193are integrally formed on stator 163 between adjacent ones of windingslots 165 with the teeth and slots extending generally axially throughthe core so as to intersect with opposite end faces 189, 191 thereof,and the teeth have generally arcuately spaced apart tips or radiallyinner ends 195 which define, at least in part, a bore 197 extendinggenerally axially through the core between the opposite end facesthereof, respectively. While twenty-six winding slots 165 are disclosedin stator 163, it is contemplated that other stators having more or lesswinding slots,as discussed hereinafter, and also having winding slots ofvarious other shapes may be utilized within the scope of the inventionso as to meet at least some of the objects thereof. Furthermore, whileteeth 193 and tips 195 thereof are illustrated herein as being generallyradially extending or straight, it is contemplated that teeth and tipsthereof having various.other shapes or positions in stator 163 could beemployed within the scope of the invention so as to meet at least someof the objects thereof. Thus, as best seen in FIGS. 13 and 14, sideportions 185 of coils 177, 179, 181 in winding stages 171, 173, 175 maybe placed or otherwise inserted either manually or by suitable automaticcoil injection equipment (not shown) generally from bore 197 of stator163 between adjacent ones of teeth 193 and tips 195 thereof into windingslots 165, respectively. Since coil side portions 185 are arrangedwithin winding slots 165, opposite end turns or end turn portions 199 ofcoils 177, 179, 181, which integrally connect with opposite side turnportions 185 thereof, are arranged so as to form a pair of opposite endturn groupings 201, 203 adjacent opposite end faces 189, 191 of stator163 extending generally about bore 197 radially outwardly thereof, asbest seen in FIG. 18.

As best seen in FIG. 14, a slot liner 205 of suitable insulatingmaterial is disposed in each of slots 165 so as to insulate side turnportions 185 of coils 177, 179, 181 disposed in respective ones of theslots from stator 163; however, it is contemplated that other types ofslot lining insulation, such as a resin insulation layer deposited on orotherwise integrally formed with the stator for instance, may beutilized within the scope of the invention so as to meet at least someof the objects thereof. Further, a slot wedge 207 of suitable insulatingmaterial is disposed across each of slots 165, so as to engage adjacentones of teeth 193 at least adjacent tips 195 thereof thereby to containside turn portions 185 of conductor turns 183 against displacement fromthe slots, respectively. Thus, due to the aforementioned windingconfiguration or arrangement of coils 177, 179, 181 of winding stages171, 173, 175, one of opposite side turn portions 185 of the coils ispositioned in a top section 209 of a respective one of slots 165 and theother of the opposite side turn portions of the coils is positioned in abottom section 211 thereof, respectively, with only the exception of thecoil side turn portions which do not share slots, as discussed in detailhereinafter. Albiet not shown, suitable insulation between windingstages 171, 173, 175 including end turn groupings 201, 203 thereof maybe utilized,if desired,within the scope of the invention so as to meetat least some of the objects thereof.

Coils 177, 179, 181 of the three winding stages 171, 173, 175 aredisposed in slots 165 of stator 163 generally in the aforementionedlapped winding configuration, FIGS. 13-15; however, it is contemplatedthat not only a greater or lesser number of winding stages but alsowinding stages having different winding configurations, such as thoseillustrated in FIGS. 15A and 15B for instance, may be employed withinthe scope of the invention so as to meet at least some of the objectsthereof. Further, it may be noted that each of coils 177, 179, 181 ineach winding stage spans three of teeth 193, i.e., coil side turnportions 185 are contained in every fourth one of slots 165; however, itis contemplated that the coils may span a greater or lesser number ofthe teeth within the scope of the invention so as to meet at least someof the objects thereof. In multi-stage winding arrangement 167, it maybe noted that coils 177-1 to 177-3 and 177-5 to 177-7 of winding stage171, coils 179-2, 179-3 and 179-5 to 179-7 of winding stage 173, andcoils 181-2 to 181-4 and 181-6 to 181-8 of winding stage 175 have one oftheir opposite side turn portions 185 sharing a respective one of slots165 with one of the side turn portions of the coils in the same windingstage. It may also be noted that coils 179-1, 179-5 and 179-2, 179-4 ofwinding stage 173 have one of side turn portions 185 thereof sharing arespective one of slots 165 with one side turn portion 185 of coils177-4, 177-8 and 181-3, 181-5 in winding stages 171, 175, respectively.Further, it may also be noted that coils 177-1, 177-5 and 181-4, 181-8of winding stages 171, 175 each have a side turn portion 185 which doesnot share a respective one of slots 165, respectively.

An alternative multi-stage winding arrangement for stator 163 is shownschematically in FIG. 15A. In this alternative winding arrangment 167a,coils 177-1 to 177-8 of winding stage 171 are disposed in the bottomsections 211 of slots 165, coils 179-1 to 179-8 of winding stage 173 aredisposed in the top sections 209 of the slots, and coils 181-1 to 181-8of winding stage 175 are disposed in the slots between theaforementioned coils in the top and bottom sections of the slots.

Another alternative multi-stage winding arrangement 167b for stator 163is shown schematically in FIG. 15B. Although alternative windingarrangement 167b is somewhat similar to winding arrangement 167a, it maybe noted that coils 177-5 to 177-8 of winding stage 171 are shifted tothe top sections 209 of slots 165 while coils 179-5 to 179-8 of windingstage 173 are shifted to the top sections 211 of the slots for reactancepurposes. Of course., coils 181-1 to 181-8 of winding stage 175 aredisposed in slots 165 between the top and bottom sections 209, 211thereof.

Referring now to FIGS. 16-18, electronically commutated motor orbrushless DC motor 45 comprises stationary assembly 161 with stator 163thereof disposed within a housing 213, and rotatable assembly 151 isarranged in magnetic coupling relation with the stator and suitablyjournaled in a pair of opposite end shields 215, 217 of the stationaryassembly which are secured to the housing, respectively.

More particularly, housing or shell 213 comprises a generally cylindricsleeve 219 which may be formed of any desired material, and the sleevehas a bore 221 extending therethrough between a pair of opposite annularend flanges 223, 225 or the like integrally formed with the sleeve. Aplurality of cooling fins 227 are integrally formed on sleeve 219externally thereof between end flanges 223, 225, and a plurality of ventholes 229 may be provided, if desired, through the sleeve adjacent theend flanges so as to intersect with sleeve bore 221, respectively.Peripheral portion 187 of stator 163 is received within sleeve bore 213being retained therein by suitable means, such as for instance apress-fit or heat shrinking between the peripheral portion of the statorand the sleeve bore. While housing 213 is illustrated for purposes ofdisclosure, it is contemplated that other housings having othercomponent parts different from those illustrated herein may be utilizedwithin the scope of the invention so as to meet the objects thereof.

End shields 215, 217 are secured to housing 213 adjacent opposite endflanges 223, 225 of sleeve 219 by suitable means, such as a plurality ofscrews 231 or the like for instance, respectively. A pair of generallycentrally located bearing openings 233, 235 extend through end shields215, 217, and a pair of bearing means, such as self-lubricating bearings237, 239 for instance, are mounted in the openings respectively. Rotor43 of rotatable assembly 151.is generally coaxially arranged withinstator bore 197 of stationary assembly 161 so as to provide apredetermined air gap 241 therebetween, and shaft extensions 157, 159 ofthe rotatable assembly extend through bearings 237, 239 so as to bejournaled thereby, respectively. Thus, it may be noted that polesections 49,53 of rotor 43 are disposed in magnetic coupling relationwith winding stages 171, 173, 175 in stator 163 which are adapted to becommutated or energized in a plurality of preselected sequences and/or aplurality of preselected different sequences, as discussed hereinafter.Albeit not shown, the commutation of winding stages 171, 173, 175 in theaforementioned plurality of preselected sequences and/or plurality ofpreselected different sequences may be effected through the connectionof such winding stages with suitable circuitry, such as for instancethat disclosed in abandoned applications of Harold B. Harms and David M.Erdman Ser. No. 077,776, filed Sept. 21, 1979 and David M. Erdman Ser.No. 077,656, filed Sept. 21, 1979, and each of these applications isincorporated by reference herein.

While stator 163 of electronically commutated motor 45 may have somecharacteristics comparable to those of a conventional A.C. motor, suchas for instance being wound by existing coil winding and placementequipment employed in the manufacture of A.C. motors, it may be notedthat the number of slots 165 employed in stator 163 to accommodatemulti-stage winding arrangement 167 is different than the product of aninteger multiplied by the number of poles in rotatable assembly 151. Inthis vein, an alternative designation of the required number of slots167 in stator 165 may be stated by the following equation:

    s=P(S)(X)±y

where

s=number of slots in stator 165;

P=number of poles in rotatable assembly 151;

S=the number of winding stages;

X=a selected integer greater than zero; and

y=an integer not less than one or greater than two.

Thus, it may be noted that the twenty-six winding slots 165 in stator163 accommodates the three winding stages 171, 173, 175 magneticallycoupled with the eight poles of rotatable assembly 151 so as to satisfythe aforementioned equation, and the number of slots in the stator,i.e., twenty-six slots, is different than the product of an integermultiplied by the eight poles of the rotatable assembly.

In the operation of electronically commutated motor 45 with reference toFIG. 19, it is desirable to provide an advanced timing angle, i.e., anadvancement of the energization of commutation of winding stages 171,173, 175, which is defined as angle α in FIG. 20. In explanation of thistiming angle advancement, zero advancement would occur in electronicallycommutated motor 45 if one of winding stages 171, 173, 175 thereof wouldbe energized at the instant the magnetic center of one of pole sections49,53 in rotor 43 rotated into a position spaced approximatelytwenty-two and one-half electrical degrees from the axis of one of themagnetic pole established by the energization of such one winding stage.Of course, zero advancement is believed to be the theoretical optimumwith zero winding stage inductance, and energization of theaforementioned one winding stage a preselected number of electricaldegrees before the theoretical optimum position of rotor 43 is attainedcomprises the advancement of commutation, i.e., advanced timing angle α.Of course, the particular advanced timing angle α selected for theoperation of electronically commutated motor 45 may be incorporated intothe aforementioned circuitry of applications Ser. No. 077,776 and Ser.No. 077,656 which, as previously mentioned, is operable to effect theswitching or energization of winding stages 171, 173, 175 in theplurality of preselected sequences and/or preselected differentsequences thereof. In further explanation, the preferred amount ofadvancement of timing angle α is associated with the L/R time constantof multi-stage winding arrangement 167. At the aforementioned zeroadvancement, current in winding stages 171, 173, 175 would build up tooslowly to achieve maximum possible torque throughout the full "on" time.Thus, advancing the commutation angle, as discussed above, takesadvantage of the fact that the generated back emf is less duringincomplete coupling, i.e., when the polar axii of rotor 43 and theenergized one of winding stages 171, 173, 175 are not in exactalignment; therefore, current build-up time and torque development canbe improved. If the advanced timing angle is too great, currentovershoots may occur thereby to adversely affect efficiency; therefore,the optimum value of the advanced timing angle depends to.some extent onthe desired speed at which electroncially commutated motor 45 isoperated and the torque desired therefor.

With continued reference to FIG. 19, assume that winding stage 171 ofmulti-stage winding arrangement 167 in electronically commutated motor45 is instantaneously energized, and under this assumption, the centersof the north and south magnetic poles established by winding stage 171have been noted as N171 and S171, respectively. The general location ofthe polar axii or centers of polar sections 49, 53 of rotor 33 aredesignated as S49, N53 and S49 and N53, respectively. If winding stages171, 173, 175 were commutated with the aforementioned zero advancementin a preselected sequence thereof, the N,S poles associated withrespective ones of the winding stages will appear and disappear as thewinding stages are energized and de-energized in the preselectedsequence thereof. Thus, as may be noted from FIG. 19, when the center ofthe magnetic poles S49, N53 of rotor 43 are positioned twenty-two andone-half electrical degrees past a like one of stator poles N171, S171,theoretically winding stage 171 should be energized at this instant soas to establish the poles N171, S171, and winding stage 171 shouldremain energized during the subsequent onehundred thirty-five electricaldegrees rotation of the rotor. Then, winding stage 171 would bede-energized. The next one of winding stages 173, 175 in the preselectedsequence would besimilarlyenergized. However, instead of commutatingwinding stages 171, 173, 175 with zero advancement in the preselectedsequence thereof, as discussed above, it is preferred to effect theoperation of electronically commutated motor 45 so that winding stages171, 173, 175 thereof are commutated in advance of the theoreticalcommutation point or angle (i.e., zero advancement) by the predeterminedadvanced timing angle α (in electrical degrees).

In the light of the foregoing discussion, the commutation orenergization of winding stages 171, 173, 175 in the preselected sequencethereof effects the magnetic coupling therewith of rotatable assembly151 causing unidirectional rotation of the rotatable assembly in theclockwise direction, as indicated by the directional arrow in FIG. 19,with respect to stator 163. It may be noted that if winding stages 171,173, 175 were so energized in a preselected sequence reverse to thatdiscussed above, the magnetic coupling of the winding stages withrotatable assembly 151 would cause a reverse unidirectional rotationthereof in the counterclockwise direction with respect to stator 163.Further, it may also be noted that the rotational speed of rotatableassembly during the unidirectional rotation thereof in both theclockwise and counterclockwise directions may be varied by varying atleast the frequency at which winding stages 171, 173, 175 are commutatedin the preselected sequence thereof. In addition, it may be furthernoted that winding stages 171, 173, 175 may be commutated or energizedin preselected different sequences effecting the magnetic couplingtherewith of rotatable assembly 151 so as to cause oscillation of therotatable assembly in both the clockwise and counterclockwise directionwith respect to stator 163. The speed of such rotatable assemblyoscillation may be varied in the same manner as discussed above, and theamplitude of such rotatable assembly oscillation may be varied byvarying the successive energization of the.winding stages 171, 173, 175during the preselected different sequences of energization thereof. Forinstance, in determining the frequency of the amplitude for theoscillation of rotatable assembly 151, it is contemplated that windingstages 171, 173, 175 could be commutated so that the rotatable assemblyacts as a generator. In other words, when winding stages 171, 173, 175are so commutated, rotatable assembly 151 then generates a voltage whichis induced into the winding stages creating a back emf thereby to effectthe termination of the oscillation movement of the rotatable assemblygenerally at the preselected amplitude of such oscillation movement. Ofcourse, the unidirectional rotation of rotatable assembly 151 may, ifdesired, also be terminated by shorting out winding stages 171, 173, 175so that the rotatable assembly acts as a generator, or if desired, thewinding stages may merely be de-energized.

FIG. 20 is a graphical representation of voltage of one winding stage,such as winding stage 171 for instance, developed by electronicallycommutated motor 45. The solid trapezoidal curve illustrates theinstantaneous voltage in winding stage 171 for a revolution through onepair of adjacent pole sections 49,53 in rotor 43. The dashed trapezoidalcurves are similarly shown for winding stages 173 and 175 to representtheir respective instantaneous voltage contributions. The heavy solidcurve displays the net affect of winding stage 171 being energized forone hundred thirtyfive electrical degrees only with winding stage 175being energized for one hundred thirty-five electrical degrees and so onfor winding stage 175. If a more detailed discussion is desired withrespect to the commutation of winding stages 171, 173, 175 to effect theoperation of electronically commutated motor 45, reference may be had tothe aforementioned U.S. Pat. No. 4,005,347.

With reference again in general to the drawings, a transmissionmechanism 245, which is adapted to be employed in a laundry or clotheswashing machine 247, is shown.in one form of the invention having ahousing or casing 249 with a pair of opposite end portions or walls 251,253 (FIGS. 21-26). Input means 255 extending through opposite endportion or wall 251 of casing 249 is operable for rotation so as tooscillate in one operating mode of transmission mechanism 245 and alsofor rotation unidirectionally in another operating mode of thetransmission mechanism (FIG. 21). A pair of generally coaxially arrangedoutput means 257, 259 extending through opposite end portion or wall 253of casing 249 are operable generally for conjoint rotation with inputmeans 255 during the one and another operating modes of transmissionmechanism 245, respectively (FIGS. 23 and 24). Means, indicatedgenerally at 261, is disposed in casing 249 for transmitting to outputmeans 257 the rotation of input means 255 during the aforementioned oneoperating mode while output means 259 is at rest and for transmitting tooutput means 259 the rotation of the input means during theaforementioned another operating mode while output means 257 is at rest,respectively.

More particularly and with specific reference to FIGS. 21-24, ncasing orcover 249 of transmission mechanism 245 encases a bearing support orhousing indicated generally at 263, disposed within a chamber 265 of thecasing. Bearing support 263 includes a pair of cylindric sidewalls 267,269 with cylindric sidewall 267 being seated on casing end wall 251. Anintermediate support wall or plate 271 is interconnected betweencylindric sidewalls 267, 269, and an upper support wall or plate 273 isconnected to the upper end of cylindric sidewall 269 generally adjacentend wall 253 of casing 249. A plurality of mounting openings 275 may beprovided in casing 249 so as to mount transmission mechanism 245 inlaundry machine 247, as discussed hereinafter. Opposite end walls 251,253 have a pair of openings 277, 279 extending threrethrough so as tointersect with chamber 265, and a pair of bearing means 281, 283 aresupported in the openings in journaling engagement with input means 255and output means 257, respectively. If desired, a plurality of mountingstuds 285 may be integrally or otherwise provided on lower end wall 251so as to extend therefrom for receiving electronically commutated motor45 when transmission mechanism 245 is mounted in laundry machine 247, asdiscussed hereinafter.

Input means 255 includes an input shaft 287 journaled in bearing means281 and extending through opening 277 in end wall 251 with a free end orend portion 289 disposed generally adjacent end wall 251 within chamber265. An input or pinion gear 291 within chamber 265 is carried on freeend 289 of input shaft 287 so as to be conjointly rotatable therewith,and the input shaft is adapted to be rotated or driven unidirectionallyand also so as to oscillate in opposite directions.

Output means 257 includes a tubular output shaft 293 having a generallyaxial bore 295 therethrough, and the tubular output shaft extendsthrough opening 279 in casing end wall 253. Output shaft 293 isjournaled in bearing means 283 in casing end wall 253 and extendsthrough support wall 273 so that a lower interior or free end of theoutput shaft is journaled in another bearing means 297 disposed inanother opening 299 extending through intermediate support 271. Anoutput, driven or pinion gear 301 is carried about tubular shaft 293 soas to be conjointly rotatable therewith, and the output gear is arrangedso as to extend from the tubular shaft generally in spaced relationbetween supports 271, 273.

Output means 259 includes an output shaft 303 which extends generallycoaxially through bore 295 of tubular shaft 293, and output shaft 303has an exterior or free end or end portion 305 exteriorly of chamber 265with an opposite interior free end or end portion 307 within thechamber, Albiet not shown, interior end 307 of output shaft 303 isjournaled in a bearing means provided therefor in casing end wall 251,and exterior end 305 of output shaft 307 may be journaled in suitablebearing means (not shown) provided therefor. Another output, driven orpinion gear 309 is carried by output shaft 303 generally adjacentinterior end 307 thereof so as to be spaced between casing end wall 251and support wall 271 within chamber 265.

Transmitting means 261 is provided for transmitting the rotationalmovement of input shaft and gear 287,291 to tubular output shaft andgear 293, 301 and to output shaft and gear 303, 309, respectively.Transmitting means 261 includes means, such as a driving or idler shaft311 and a pinion gear 313 carried thereon, associated in coupledrelation with output shaft and gear 303, 309 for driving it, and means,such as a driven or idler shaft 315 and a pinion gear 317 carriedthereon, associated in coupled relation with input shaft and gear287,291 for being driven by it. Driving and driven means or idler shafts311, 315 each have a pair of opposite end portions 319,321 and 323, 325journaled in a pair of bearing means 327 329 and 331, 333 with bearingmeans 327, 331 being disposed in casing end wall 251 and bearing means329 333 being disposed in upper support wall 273, respectively. Drivenidler shaft 315 has a plurality of splines 335 extending axiallythereabout between opposite ends 323, 325 of the driven idler shaft, andpinion gear 317 is carried on the driven idler shaft generally adjacentlower opposite end 323 thereof in meshing engagement with input gear291. Thus, the mesh between input gear 291 and pinion gear 317 effectsthe concerted driven rotation of idler shaft 315 with input shaft 287.Pinion gear 313 is carried on driving idler shaft 311 so as to bearranged in meshing engagement with output gear 309 on output shaft 303,and therefor the meshing engagement between pinion gear 313 and outputgear 309 effects the conjoint driven rotation of output shaft 303 withthe driving idler shaft, as discussed hereinafter. Another pinion gear337 is also carried on idler shaft 311 generally in spaced relation withpinion gear 313 thereon.

Transmitting means 261 also includes means, such as a pair ofinterconnected stepped shifting gears 339, 341 selectively movablebetween a plurality of shifted positions with respect to idler shafts311, 315 and operable generally in one of the shifted positions (as bestseen in FIG. 21) for coupling idler shaft 315 with tubular output shaft293 and in another of the shifted positions thereof (as best seen inFIG. 22) for coupling idler shaft 315 with idler shaft 311. A splinedbore 343 is coaxially provided through coupling means or steppedshifting gears 339, 341, and splines 335 on idler shaft 315 arecooperatively received in the splined bore so that the stepped shiftinggears are axially movable between at least the upper shifted or spinposition and the lower shifted or agitating position thereof on idlershaft 315. As discussed hereinafter, stepped shifting gears 339, 341 mayalso be provided with a third shifted position, such as aneutral or pumpoperating position, disengaged from output shafts 293, 303. Thus,through the engagement of splines 335 on idler shaft 315 with splinedbore 343 of stepped shifting gears 339, 341, the stepped shifting gearsare not only axially movable or shiftable on idler shaft 315 but alsoconjointly rotatable therewith in response to the rotation of inputshaft 287. Larger stepped shifting gear 341 is arranged in meshingengagement with output gear 301 on tubular output shaft 293 when steppedshifting gears 339, 341 are in the upper shifted position thereof, andsmaller shifting gear 339 is arranged in meshing engagement withintermediate pinion gear 337 on idler shaft 311 when the steppedshifting gears are in the lower shifted position thereof. To completethe description of transmission mechanism 245, a shift actuating device,schematically shown and indicated generally at 345, is selectivelyoperable for moving a linkage 347 thereof to effect the shifting axialmovement of stepped shifting gears 339, 341 connected with the leakagebetween the shifted positionsof the stepped shifting gears on idlershaft 315; however, while the shift actuating device and linkage areillustrated herein in association with stepped shifting gears 339, 341,for purposes of disclosure, it is contemplated that other means may beemployed for effecting the shifting of the stepped shifting gearsbetween the shifted positions thereof, i. e., shifting transmissionmechanism 245 between its aforementioned operating modes, within thescope of the invention so as to meet at least some of the objectsthereof.

With respect to the operation of transmission device 245, it will berecalled that input shaft 287 may be driven or operated so as to beoscillatable in one operating mode of the transmission mechanism andunidirectionally rotated in another operating mode of the transmissionmechanism. When input shaft 287 is unidirectionally rotated, linkage 347is actuated by shifting device 345 so that stepped shifting gears 339.341 are in the upper shifted position thereof (as best seen in FIG. 21)wherein larger stepped shifting gear 341 is meshed with output gear 301of tubular output shaft 293. In this manner, unidirectional rotation ofinput shaft 287 is transmitted through meshed input gear 291 and piniongear 317 to idler shaft 315 to effect the conjoint unidirectionalrotation thereof with the input shaft. Since splines 335 on idler shaft315 are received in splined bore 383 of stepped shifting gears 339,341,the stepped shifting gears are conjointly unidirectionally rotated withidler shaft 315, and this conjoint unidirectional rotation of theshifting gears is transmitted through meshed larger stepped shiftinggear 341 to output gear 301 on tublular output shaft 293 so as to effectthe conjoint unidirectional rotation thereof with the stepped shiftinggears. Thus, in the one operating mode of transmission mechanism 245 asdetermined by shifting device 345, the unidirectional rotation of inputshaft 287 is transmitted to tubular output shaft 293 effecting theconjoint unidirectional rotation thereof with the input shaft whileoutput shaft 303 remains at rest.

When linkage 347 is actuated by shifting device 345 so as to axiallymove stepped shifting gears 339, 341 downwardly toward its lower shiftedposition on idler shaft 315 (as best seen in FIG. 22), larger steppedshifting gear 341 is disengaged from output gear 301 on tubular outputshaft 293, and smaller stepped shifting gear 339 is moved into meshingengagement with intermediate pinion gear 337 on idler shaft 311. Withstepped shifting gears 339, 341 in their lower shifted position,transmission mechanism 245 may function in its another operating madewith input shaft 287 being oscillatally rotatable. Thus, the oscillationof input shaft 287 is transmitted through meshed input gear 291 andpinion gear 317 to idler shaft 315 to effect the conjoint oscillationthereof with the input shaft. Since splined bore 343 of stepped shiftinggears 339, 341, is received on splines 335 of idler shaft 315, thestepped shifting gears are conjointly oscillated with idler shaft 315,and such conjointoscillation is transmitted to idler shaft 311 throughthe meshing engagement of smaller stepped shifting gear 339 withintermediate gear 337 on idler shaft 311. This conjoint oscillation ofidler shaft 311 with idler shaft 315 is transmitted to output shaft 303through the meshing engagement of pinion gear 313 on idler shaft 311with output gear 309 on output shaft 303. Thus, the oscillation of inputshaft 287 is transmitted to output shaft 303 during the anotheroperating mode of transmission mechanism 345.

In the foregoing description of transmission mechanism 245, casing 249may contain a suitable lubricant (not shown) for lubricating thecomponents and bearing means thereof; however, it is contemplated thatat least the various gears of such components may be formed from a resinmaterial within the scope of the invention so as to meet at least someof the objects thereof, and if so, then the casing and the lubricant maybe omitted, and such bearing means may be of the self-lubricated type.

With reference again to the drawings in general and recapitulating atleast in part with respect to the foregoing, laundry or clothes washingmachine 247 in one form of the invention has a cabinet 351, and means,such as a perforate spin tub 353 or the like for instance, arrangedwithin the cabinet for receiving water and clothes (not shown) to belaundered therein is adapted to be unidirectionally rotatable at avelocity great enough to centrifugally displace at least some of thewater from the clothes to be laundered therein (FIG. 25). Means, such asan agitator 355 or the like for instance, arranged within receivingmeans or spin tub 353 so as to be generally coaxial therewith is adaptedto be oscillated, i.e., rotated in opposite directions, for agitatingthe clothes in the water to effect the laundering thereof (FIG. 25).Electronically commutated motor 45 mounted within cabinet 351 hasstationary assembly 163 with winding stages 171, 173, 175 wound thereinand adapted to be commutated so as to be excited or energized in atleast one preselected sequence and in at least one of preselecteddifferent sequences (FIGS. 16-19, 25 and 26). Rotatable assembly 151 isarranged with stationary assembly 163 in magnetic coupling relation withwinding stages 171, 173, 175, and the rotatable assembly is oscillatedupon the energization of the winding stages in the at least onepreselected different sequences and also unidirectionally rotated uponthe energization of the winding stages in the at least one preselectedsequence (FIGS. 16-19, 25 and 26). Transmission mechanism 245 is adaptedto be operatively connected with each of spin tub 353 and agitatingmeans or agitator 355 for transmitting the oscillation movement ofrotatable assembly 165 to the agitator so as to effect the conjointoscillation movement thereof with the rotatable assembly and fortransmitting the unidirectional rotation of the rotatable assembly tothe spin tub so as to effect the conjoint unidirectional rotationthereof with the rotatable assembly, respectively (FIGS. 21-26). Inputshaft 287 of transmission mechanism 245 is constituted by shaft 155 ofrotatable assembly 151 (FIG. 25).

More particularly and with specific reference to FIGS. 25 and 26,cabinet 351 of laundry machine 247 has a base 357 with a plurality ofadjustable or leveling support feet 359 thereon. An outer or uppercabinet structure 361 has the lower end portion thereof supported on orotherwise connected to base 357 by suitable means, and the upper endportion of the upper cabinet structure supports or is otherwiseconnected with a cover 363 therefor. Sealing means, such as a resilientgasket 365 or the like for instance, is sealably fitted or otherwiseinterposed between the upper end portion of cabinet structure 361 andcover 363.

Laundry machine 247 is provided with a supporting frame 367 on whichtransmission mechanism 245, electronically commutated motor 45, a pumpdevice 369 for the laundry machine, spin tub 353 and agitator 355 aresupported generally in vertically aligned or in-line relation,asdiscussed hereinafter. Frame 367 is suspended or otherwise mountedwithin cabinet 351 on a plurality of brackets 371 suitably attached tobase 357 by a plurality of damping means 373; however, for the sake ofdrawing simplicity only one of such bracket and damping means is shownin FIG. 25. Each vibration damping means 373 has resilient means, suchas a coil spring 375 or the like for instance, biased or otherwiseinterconnected between bracket 371 and frame 367,and other resilientmeans, such as a generally U-shaped spring clamp 377 or the like forinstance, is secured to the bracket having a pair of dependingprestressed legs 379 straddling a part 381 of the frame in grippingengagement therewith with resilient friction pads 383 interposed betweenthe legs and the fraxe part,respectively. Thus, vibration damping means373 acts not only to limit or damp twisting or torquing movement butalso vertical movement of frame 367 which may be imparted theretoparticularly during the spin cycle or operating mode of laundry machine247, as discussed hereinafter.

A platform or other upstanding structure 385 is generally centrallyprovided on frame 367 and integrally connected thereto by suitable means(not shown), and lower end wall 251 on casing 249 of transmissionmechanism 245 is seated on an upper free end or seat 287 of the platformbeing connected thereto by suitable means, such as a plurality of nutsand bolts 389 or the like for instance, arranged with mounting openings275 in the lower end wall and aligned mounting openings 391 in theplatform as best seen in FIG. 26. Further with respect to FIG. 26, itmay be seen that end shield 215 of electronically commutated motor 45 isremoved from housing 213 thereof, and flange 223 of housing sleeve 219is abutted against lower end wall 251 of transmission mechanism casing249 being secured by suitable means, such as a plurality of nuts 393 orthe like for instance, threadedly received on stud plurality 285extending from the lower end wall. Thus with electronically commutatedmotor 45 mounted to transmission mechanism 245 so as to depend therefromthrough platform 385 toward frame 367, shaft extension 157 on rotatableassembly shaft 151 in electronically commutated motor 45 is journaled inbearing means 281 disposed in lower end wall 251 of transmissionmechanism casing 249 so as to constitute input shaft 287 of thetransmission mechanism, and of course, input gear 291 is mounted onthefree end of shaft extension 157 so as to be conjointly rotatable withrotatable assembly 151 of the electronically commutated motor upon theenergization thereof. The other end shield 217 of electronicallycommutated motor 45 may also be removed so that flange 225 of housingsleeve 219 is abutted against pump 369, and the other shaft extension159 of rotatable assembly 151 extends into driving engagement with thepump of laundry machine 247. Pump 369 is secured to flange 225 ofelectronically commutated motor 45 by suitable means, such as aplurality of nuts 395 or the like for instance, threadedly received on astud plurality 397 extending from the pump. While the aforementionedmounting arrangements or interconnections of transmission mechanism 245to platform 385, electronically commutated motor 45 to the transmissionmechanism, and pump 369 to the electronically commutated motor have beenillustrated herein for the purposes of disclosure, it is contemplatedthat various other mounting arrangements or interconnections may be madebetween such components of laundry machine 247 within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again to FIG. 25, spin tub 353 includes a generallyannular perforate sidewall 399 having a base wall 401 integrallyinterconnected therewith, and a generally central opening 403 extendsthrough the base wall. Means, such as a collar 405 or the like forinstance, is provided for securing spin tub 353 to tubular output shaft293 of transmission mechanism 245, and the securing means or collarextends through opening 403 in spin tub base wall 401 being grippinglyand sealably engaged with the opposite sides thereof generallyabout theopening. Albeit not shown, the tubular output shaft 293 extendingexteriorly of transmission mechanism casing 249 is connected by suitablemeans with collar 405 so that spin tub 353 is conjointlyunidirectionally rotatable with the tubular output shaft during the spincycle of laundry machine 247, as discussed hereinafter. Further upperend 305 of output shaft 303, which extends exteriorly of transmissionmechanism casing 249 and coaxially through tubular output shaft 293, isconnected by suitable means (not shown) with agitator 355 so that theagitator is conjointly oscillated with output shaft 303 during theagitation cycle or operating mode of laundry machine 247, as alsodiscussed hereinafter.

An intermediate or enclosing tub 407 is provided with a sidewall 409spaced generally between spin tub sidewall 399 and upper cabinetstructure 361, and a base wall 411 is integrally formed with theenclosing tub sidewall having a generally centrally located openingtherethrough defined by an integral generally annular flange 413depending from the base wall in spaced relation generally adjacentcasing 249 of transmission mechanism 245. Sealing means, such as aresilient annular boot 415 or the like for instance, is sealablyinterconnected or otherwise interposed between flange 413 on enclosingtub 407 and casing 249 of transmission mechanism 245, and anothergenerally annular flange 417 integrally formed on enclosing tub sidewall409 about the free or upper end thereof extends into supportingengagement with the upper end portion of upper cabinet structure 361 andsealing engagement with gasket 365 extending thereabout. To complete thedescription of laudndry machine 247, conduit means, such as a hose 419or other flexible connection for instance is connected between base wall411 of enclosing tub 407 and pump 369 providing a passage for theremoval fromthe enclosing tub of water selectively discharged into spintub 353 through a nozzel 421.

In the operation of laundry machine 247, assume that stepped shiftinggears 339, 341 in transmission mechanism 245 are disposed in the lowershifted or agitation position thereof with smaller stepped shifting gear339 driving output shaft 303 through the meshing engagement of thesmaller shifting gear with intermediate gear 337 on idler shaft 311 andthe meshing engagement of pinion gear 313 thereon with output gear 309on the output shaft, as discussed hereinabove with respect to FIGS.21-24. With transmission mechanism 245 so set or shifted to effect theagitation cycle or operating mode of laundry machine 247, water may beintroduced through nozzle 421 into spin tub 353 so that it flows throughthe perforations therein into enclosing tub 407, and clothes to belaundered in the water and a charge of detergent or the like (not shown)may also be placed in the spin tub. Of course, the level to which thewater rises in enclosing tub 407 may be controlled by any suitable fluidlevel sensing means, as well known in the art. With this preparation,electronically commutated motor 45 may be energized to commence the washor agitation cycle of laundry machine 247. Upon the energization ofelectronically commutated motor 45, winding stages 171, 173, 175 of theelctronically commuted motor are commutated so as to be excited in theaforementioned preselected different sequences which effects themagnetic coupling therewith of rotatable assembly 151 so as to impartoscillating movement or rotation to the rotatable assembly. Of course,as previously mentioned, this oscillating rotation of rotatable assembly151 may be of any desired or preselected speed depending upon thefrequency of the commutation of winding stages 171, 173, 175 and also ofany desired or preselected amplitude depending upon the time or numberof cylces the frequency is applied to the winding stages. Theoscillating rotation of rotatable assembly 151 is translated ortransmitted by transmission mechanism 245 to its output shaft 303 whichis drivingly connected or otherwise associated with agitator 355 so asto effect the conjoint oscillation thereof with the rotatable assemblyof electronically commutated motor 45. In this manner, the oscillatorymovement of agitator 355 within spin tub 353 effects the agitation andlaundering of the clothes therein. Albeit not shown for purposes ofbrevity, pump 369 may include means for pumping water from enclosing tub407 through a filter back into spin tub 353 in order to trap or filterout much of the lint which may be separated from the clothes as they arelaundered during the above discussed agitation cycle of laundry machine247. After laundry machine 247 has been operated for a desired orpreselected period of time in its agitation cycle, electronicallycommutated motor 45 may be de-energized so as to terminate suchagitation cycle.

Subsequent to the agitation cycle of laundry machine 247 and in order toinitiate the spin cycle thereof, shifting device 345 for transmissionmechanism 245 may be actuated causing its linkage 347 to move steppedshifting gears 339, 341 upwardly on idler shaft 315 toward the spin orupper shiftedposition thereof, as shown in FIG. 21, so that largerstepped shifting gear 341 is meshed with output gear 301 on tubularoutput shaft 293. At this time, electronically commutated motor 45 maybe reenergized with its winding stages 171, 173, 175 commutated so as tobe excited in a preselected sequence which effects the magnetic couplingtherewith of rotatable assembly 151 in the manner discussed hereinbeforeto impart unidirectional rotation to the rotatable assembly. Aspreviously mentioned, the unidirectional speed of rotatable assembly 151may be of any desired or preselected speed depending upon the thefrequency with which winding stages 171, 173, 175 of electronicallycommutated motor 45 are commutated in the preselected sequence duringthe spin cycle of laundry machine 247; however, it is contemplated thatthe speed of the unidirectional rotation of the rotatable assembly willbe appreciably greater than the speed of the above discussed oscillationrotation of the rotatable assembly. With stepped shifting gears 339,341, moved into the upper shifted position thereof in transmissionmechanism 245, as discussed above, the unidirectional rotation ofrotatable assembly 151 is translated or transmitted by the transmissionmechanism to its tubular output shaft 293 which is drivingly connectedor otherwise associated with spin tub 353 so as to effect the conjointunidirectional rotation thereof with the rotatable assembly ofelectronically commutated motor 45. In this manner, the unidirectionalrotation of spin tub 353 is operative to effect the centrifugaldisplacement of water from the clothes within the spin tub, and ofcourse, pump 369 may, if desired, be arranged to be driven byelectronically commutated motor 45, as discussed hereinafter, andincludes means for effecting the removal of water from the spin tub andenclosing tub 407 through hose 419 to a drain (not shown). After laundrymachine 247 has been operated for a desired or preselected period oftime in its spin cycle, electronically commutated motor 45 may bede-energized so as to terminate such spin operating mode.

To complete the operation of laundry machine 247, shifting device 345may be selectively actuated to operate linkage 347 and move steppedshifting gears 339, 341 to the neutral position thereof, as previouslymentioned, to effect a pumping cycle or mode of operation of the laundrymachine. In their neutral position, stepped shifting gears 339, 341 aredisengaged from output gear 301 on tubular output shaft 293 and fromintermediate gear 337 on idler shaft 311 which is drivingly connectedwith through its gear 313 with output gear 309 on output shaft 303.Therefor, withstepped shifting gears 339, 341 in their neutral position,electronically commutated motor 45 may be energized to drive pump 369while being, in effect, drivingly disconnected from spin tub 353 andagitator 355 by transmission mechanism 245.

It will be understood that while the above description of laundrymachine 247 does not illustrate all of the valving and particularcontrols normally provided on modern domestic laundry machines, theomission and/or simplification of these components is primarily for thepurposes of brevity; however, it is contemplated that such componentsmay be provided in the laundry machine and that such laundry machine maybe provided with other operating modes or cycles within the scope of theinvention so as to meet at least some of the objects thereof.

With reference again in general to the drawings and recapitulating withrespect to the foregoing, it may be noted that a drive in one form ofthe invention is provided for laundry machine 247 (FIGS. 13-20 and21-26). In this drive, transmission mechanism 245 has input means 255adapted for both oscillating and unidirectional rotation, and coaxiallyarranged output means 257, 259 of the transmission mechanism are adaptedfor selective driven connection with the input means so as to beconjointly rotatable therewith, respectively (FIGS. 21-26).Electronically commutated motor 45 is associated in mounting relationwith transmission mechanism 245 and includes rotatable assembly 151connected generally in aligned and direct driving relation with thetransmission so as to comprise the input means 255 thereof (FIGS. 25 and26). Electronically commutated motor 45 further includes multi-stagewinding arrangement 167 with each winding stage 171, 173, 175 thereofbeing selectively energizable to effect both oscillation andunidirectional rotation of rotatable assembly 151 thereof (FIGS. 13-20).

Referring now to FIGS. 27 and 28, alternative pole sections 53a and 53bare shown assembled in rotor 43 by generally the same method of makingthe rotor as discussed hereinabove and having generally the samecomponent parts functioning in generally the same manner as thepreviously discussed pole section 53 with the following exceptions;however, while pole sections 53a and 53b may meet at least some of theobjects set out hereinabove, it is believed that pole sections 53a and53b also have indigenous objects and advantageous features which will bein part apparent and in part pointed out in the following discussion.

In pole sections 53a of FIG. 27, a generally T-shaped opening 431 isprovided therethrough in which hardenable material 93 is received andsolidified when provided in slots 99 of rotor 43 or otherwise introducedthereinto, as previously discussed with respect to the method of makingthe rotor and as indicated in functional diagram box 133 of FIG. 2.Thus, the abutment of hardenable material 93 with flanges 141, 143 ofpole sections 49 and the coaction of the hardenable material withT-shaped opening 431 in pole sections 53a serves to retain both the polesections 53a and magnets 89, 91 against displacement from thepreselected or located positions thereof within rotor slots 99. It maybe noted that seats 83, 85 provided on the previously discussed polesection 53 for seating abutment with magnets 89, 91 may be omitted frompole section 53a due to the retaining relationship of T-shaped opening431 thereof with hardenable material 93 in rotor slots 99. WhileT-shaped opening 431 in pole section 53a is shown for purposes ofdisclosure, it is contemplated that other shaped openings may beprovided in other pole sections for the retaining relationship withhardenable material 93 in rotor slots 99 within the scope of theinvention so as to meet at least some of the objects thereof. Of course,one of those contemplated openings is shown at 433 in pole section 53bof FIG. 28. In opening 433, opposed serrations 435, 437 are provided onpole sections 53b in generally the same retaining relation withhardenable material 93 in rotor slots 99 as discussed above with respectto pole sections 53a.

Referring now to FIGS. 29-32, there is disclosed an alternativerotatable assembly 451 for use in electronically commutated motor 45 andalso an alternative method of making, manufacturing or assembling a coreor rotor 453 in one form of the invention which may be utilized in therotatable assembly. This alternative method and rotatable assembly 451utilizes generally the same component parts arranged so as to functiongenerally in the same manner as the previously discussed method androtatable assembly 151 with the exceptions discussed hereinafter;however, while this alternative method and rotatable assembly 451 maymeet at least some of the objects set out hereinabove, it is believedthat the alternative method and rotatable assembly 451 also haverespective indigenous objects and advantageous features which will be inpart apparent and in part pointed out in the following discussion.

With reference to FIGS. 29 and 30, rotor 453 includes a stack 455 oflaminations 457 arranged generally in juxtaposed or face-to-facerelation in a desired stack length or height. Each lamination 457 has aunitary, body 459 of generally thin ferromagnetic magnetic material, anda pair of radially spaced outer and inner peripheral edges 461, 463 areprovided on the body with the inner peripheral edge defining a shaftreceiving opening. A plurality of openings, such as generally U-shapedor V-shaped apertures or slots 465 for instance, are provided throughbody 459 intersecting with outer peripheral edge 461, and the openingsare arranged with each other in generally arcuate spaced relation aboutthe body. Thus, a plurality of pole sections 467 are respectivelydefined on body 459 between adjacent ones of openings 465 so as toextend between outer and inner peripheral edges 461, 463, and aplurality of means, such as inner peripheral bridges or connecting arms469 for instance, on the body are interposed or otherwise integrallyinterconnected between adjacent ones of pole sections 467 for bridgingtherebetween generally adjacent the inner peripheral edge.

As previously mentioned, each of openings 465 intersect with outerperipheral edge 461, and the openings include a pair of opposed sideedges 471, 473 extending generally in converging relation with respectto each other between outer and inner peripheral edges 461, 463 with anend edge 175 interconnected between the opposed side edges and spacedgenerally adjacent the inner peripheral edge. Thus, bridges 469 aredefined on body 459 generally between end edge 475 of openings 465 andinner peripheral edge 463, and pole sections 467 are defined on the bodygenerally between opposite ones of side edges 471, 473 of adjacentopenings 465, respectively. A pair of opposed extensions or flanges 477,479 are integrally provided on adjacent ones of pole sections 467 atleast adjacent outer peripheral edge 461 and the flanges extend intoopenings 465 past opposed side edges 471, 473 thereof. While openings465 are described herein as being generally V-shaped, it is contemplatedthat other openings having various other shapes may be employed in otherlaminations within the scope of the invention so as to meet at leastsome of the objects thereof.

A plurality of other pole sections 481 may be formed from generally thesame ferromagnetic material as that of lamination body 459, and each ofpole sections 481 is generally V-shaped so as to generally correspond toor fit within openings 465, as discussed in greater detail hereinafter.Pole sections 481 include a generally arcuate edge 483 formed so as tohave generally the same radius of curvature as outer peripheral edge 461on lamination body 459, and the arcuate edge interconnects between oneof the ends a pair of opposite side edges 485, 487 on pole section 481,respectively. Opposite side edges 485, 487 extend generally convergentlyfrom arcuate edge 483, and the other of the ends of the opposite sideedges are interconnected with free end edge 489 which is generallyopposite arcuate edge 483. To complete the description of laminations457 and pole sections 477, a plurality of amortisseur winding receivingapertures 491 are provided through the laminations and the polesections.

With reference in general to FIGS. 29-32 and recapitulating at least inpart with respect to the foregoing, there is illustrated a method ofmaking, manufacturing or assembling rotor 453, and the rotor has aplurality of discrete polar regions or areas, such as generally definedby pole sections 467 for instance, with such polar regions or polesections being spaced apart generally about a peripheral portion 493 ofthe rotor (FIGS. 29, 30 and 32). In this method, a plurality of otherdiscrete polar regions or areas, such as defined by pole sections 481for instance, are positioned or otherwise placed or located inpreselected positions between adjacent ones of pole sections 467, and aplurality of sets of magnetic material elements, such as magnets 89, 91for instance are disposed or otherwise arranged between pole sections481 and the pole section 477 adjacent thereto, respectively (FIGS. 30and 32). A hardenable nonmagnetic material 495 is solidified in place inrotor 453 between pole sections 467, 481 and magnets 89, 91 so as notonly to effect magnetic polarity definition between pole sections 467and pole sections 481 but also to retain pole sections 481 againstdisplacement from the preselected positions thereof, respectively (FIG.33). While hardenable nonmagnetic material 495 as discussed above isdisclosed as a resin material, it is contemplated that other hardenablenon-magnetic material.s, such as aluminum, copper or alloys thereof forinstance, may be employed in the method of making rotor 453 within thescope of the invention so as to meet at least some of the objectsthereof.

More particularly and with specific reference to FIGS. 29-32, aplurality of laminations 457 are stacked or otherwise assembled togethergenerally in juxtaposed or face-to-face relations thereby to formlamination stack 455, as shown in FIG. 29, and such stacking of thelaminations is illustrated by functional diagram box 497 in FIG. 31.Either during or subsequent to the above discussed stacking oflaminations 457 into rotor stack 455, openings 465 and apertures 491 ofeach of the laminations are respectively aligned or otherwise arrangedor located with respect to each other so that such aligned openingsdefine a plurality of slots or slot openings 499 and so that suchaligned apertures define a plurality of amortisseur winding receivingopening or bores 501 which extend across or through rotor stack 455between a pair of opposite ends or end faces 503, 505 thereof,respectively. Even though the alignment of openings 465 and apertures491 so as to respectively form slots 499 and bores 501 may beaccomplished during the stacking of laminations 457, as discussed above,such alignment is illustrated in a separate functional diagram box 507in FIG. 31 for purposes of clarity. Further, albeit not shown for thesake of brevity, it is understood that suitable equipment may beemployed to effect the stacking of laminations 57 and the alignment ofopenings 465 and apertures 91, as discussed above. Of course, it mayalso be noted that upon the alignment of openings 465 and apertures 491,outer and inner peripheral edges 461, 463 of laminations 457 in stack455 thereof are also generally aligned or otherwise arranged with eachother so that the outer peripheral edges define in part peripheralportion or wall 493 on rotor 453 between opposite ends 503, 505 thereofand inner peripheral edges 463 generally define a shaft receiving bore509 extending through the rotor between the opposite end thereof,respectively, as best seen in FIG. 29. The particular edges onlaminations 457 which define openings 465 therethrough, as discussedabove, are also disposed generally in alignment with each other upon thealignment of the openings so as to form slots 499 in rotor stack 455,and such particular edges in their aligned formation define walls orwall means of the slots; however, for the sake of brevity, such slotwalls will be designated by the reference numerals of such particularedges corresponding thereto when referred to hereinafter.

Either before, after or simultaneously with the above discussed stackingof laminations 457 and the alignment of openings 465 so as to definerotor slots 499, a plurality of pole sections 481 may also be stacked orotherwise assembled together generally in juxtaposed or face-to-facerelations thereby to form a plurality of stacks 511 thereof, as bestseen in FIGS. 29 and 32, with the pole section stacks having generallythe same stack lengths or heights as lamination stack 455. Of course,either during such stacking of pole sections 481 or subsequent thereto,the particular edges on the pole sections are respectively aligned witheach other so as to define walls or wall means on the pole section stack511; however, for the sake of brevity, such pole section walls will bedesignated by the reference numerals of such particular edgescorresponding thereto when referred to hereinafter. When the particularedges of pole sections 81 are so aligned, apertures 491 extendingtherethrough are also aligned with each other so as to define otheramortisseur winding receiving bores 501 through pole sections stacks511. Since the stacking and aligning of pole sections 481 may occurbefore, after or simultaneously with the stacking of laminations 457, aspreviously mentioned, the pole section stacking and aligning arerespectively illustrated by functional diagram boxes 513 and 515 in FIG.31 in parallel flow relation with box 493 which illustrates thelamination stacking. Albeit not shown for the purpose of brevity, it isunderstood that suitable equipment may be employed to effect thestacking and alignment of pole sections 481 into stacks 511 thereof.

Subsequent to the stacking and aligning of laminations 457 and polesections 481, as discussed above, a plurality of amortisseur windingbars 517 of a nonmagnetic material yet having good electricalconductivity properties, such as aluminum, copper or alloys thereof forinstance, may be inserted or otherwise placed or located in bores 501extending through both lamination stack 455 and pole section stack 511,as best seen in FIGS. 29 and 32. Of course, the insertion of bars 517through lamination stack 455 and pole section stacks 511 may occursimultaneously or one before the other, as desired; therefore, theinsertion of the bars into the lamination stack and the pole sectionstacks are respectively illustrated in functional diagram boxes 519 and521 in parallel flow relation with each other in FIG. 31. While bars 517are disclosed herein as being inserted into bores 501 of both laminationstack 455 and pole section stack 511 subsequent to the respectivestacking and aligning thereof, it is contemplated that the bores of boththe laminations 457 and pole sections 477 may be assembled directly ontoor about the bars arranged in predetermined positions so as toaccommodate the stacking and alignment of the laminations and the polesections thereon within the scope of the invention so as to meet atleast some of the objects thereof. Of course, it is also contemplatedthat suitable equipment and/or fixtures (not shown) may be utilized toeffect the placement of bars 517 with respect to bores 501 in laminationstack 457 and pole section stacks 511, respectively.

With bars 517 so placed in lamination stack 457 and pole section stacks511, the pole section stacks may be disposed, placed or otherwiselocated within slots 499 of lamination stack 455 in preselectedpositions therein. In these preselected positions, it may be noted thatopposite sidewalls. 485,.487 of pole sections stacks 511 are arrangedgenerally in opposed facing relations with opposed sidewalls 471, 473 onadjacent ones of pole sections 467 on the lamination stack, and arcuatewalls 483 of the pole section stacks are arranged so as to generallydefine in part peripheral portion 493 of rotor 453 or at least begenerally coextensive therewith. Of course, free end walls 489 of polesection stacks 511 are disposed in spaced relation opposite end walls475 of lamination stack 455 when the pole section stacks are in theirrespective preselected positions. The disposition of pole section stacks511 in their respective preselected positions is illustrated byfunctional diagram box 523 in FIG. 31.

Either before, after or simultaneously with the placement of polesection stacks 511 in their preselected positions, as discussed above,sets of magnets 89, 91 may also be disposed, placed or otherwise locatedin preselected positions between opposite sidewalls 185, 187 of the polesection stacks and opposed sidewalls 171, 173 of pole sections 467 onlamination stack 455 adjacent the pole section stacks, respectively.Albeit desirable to abut opposite sidewalls 185, 187 of pole sectionstack 511 and opposite faces 109 of the magnets with opposed sidewalls171, 173 of pole sections 467 on lamination stack 455, it is believedthat the magnets may be generally loosely disposed therebetween, i. e.,with respect to the manufacturing tolerances of the magnets, the polesection stack and the lamination stack, respectively. Of course, it iscontemplated that suitable equipment and/or fixturing may be employed toprovide for the location of pole section stacks 511 and magnets 89, 91either simultaneously or in any order about rotor 453. Even thoughmagnets 89, 91 may be located in their respective preselected positionseither before, after or simultaneously with the placement of polesection stacks 511 in their respective preselected positions, aspreviously mentioned, the location of the magnets is illustrated forpurpose of clarity in functional diagram box 525 in FIG. 31 separatefrom box 523 which illustrates the location of the pole section stacks.If laminations 457 and pole sections 481 are assembled into respectivestacks 455 and 511 thereof on bars 517, as contemplated and previouslymentioned hereinabove, it is further contemplated that magnets 89, 91may be assembled with the respective stacks while they are mounted onthe bars within the scope of the invention so as to meet at least someof the objects thereof.

Subsequent to the location of magnets 89, 91 with respect to laminationstack 455 and pole section stack 511, as discussed above, a pair of endrings 527, 529 are positioned or otherwise mounted generally inface-to-face relation with opposite end faces 503, 505 of the laminationstack and on the opposite ends of bars 517 extending through bores 501in both pole section stacks 511 and the lamination stack past the endfaces thereof, respectively. End rings 527, 529 are formed of anonmagnetic material having acceptable electrical conduct properties,such as aluminum, copper or alloys thereof for instance, and a pluralityof apertures 531 are provided through the end rings generally inalignment with bores 501 in both lamination stack 455 and pole sectionstacks 511 so as to receive the opposite ends of bars 517 when the endrings are mounted thereto, respectively. End rings 527, 529 arerespectively provided with generally radially spaced outer peripheraledges 533 and inner peripheral edges 535, and the outer peripheral edgesare disposed at least adjacent peripheral portion 493 of rotor 453 whilethe inner peripheral edges are disposed at least adjacent shaftreceiving bore 509 of the rotor. The mounting of end rings 527, 529, asdiscussed above, is illustrated by functional diagram box 537 in FIG.31, and of course, it is also contemplated that suitable equipmentand/or fixturing (not shown) may be employed to effect the mounting ofthe end rings.

With opposite ends of bars 517 so received in apertures 531 of end rings527, 529, the bars and end rings are secured together in displacementpreventing engagement and electrical contacting engagement by suitablemeans, such as soldering or the like for instance, thereby to formamortisseur winding 539 in rotor 453; however, it is contemplated thatother means may be employed to effect the securement of the bars and theend rings within the scope of the invention so as to meet the objectsthereof. The securement of end rings 527, 529 to bars 517, as discussedabove, is illustrated by functional diagram box 541 in FIG. 31.

When end rings 527, 529 are so mounted in caging relation withlamination stack 455 and pole section stacks 511 and secured to theopposite ends of bars 517, as previously discussed, hardenablenonmagnetic material 495 is provided or otherwise introduced into slots499 of lamination stack 455 between the end rings so as to fill theinterstices within the slots between pole section stacks 511, polesections 467 on the lamination stack and magnets 89, 91 disposedtherebetween, as best seen in FIG. 33 and as illustrated by functionaldiagram box 543 in FIG. 31. As previously mentioned, upon thesolidification of hardenable material 495 in slots 499, the hardenablematerial and magnets 89, 91 define the magnetic polarity of pole sectionstacks 511 from that of pole sections 467 on lamination stack 455, andsince the hardenable material is engaged between opposite faces 113 ofthe magnets and flanges 477, 479 on the lamination stack, the hardenablematerial also serves to maintain or retain the magnets in theirpreselected positions against displacement therefrom respectively. It isalso believed that the hardenable material may assist the amortisseurwinding 539 in retaining pole section stacks 511 against displacementfrom their respective preselected positions in slots 499.

To complete the method of making rotor 453, peripheral portion 493thereof may be turned or otherwise machined so as to provide the rotorwith a preselected outside diameter generally in the same manner asdiscussed hereinabove with respect to the machining of rotor 43.

Upon the completion of rotor 453, bore 509 thereof may be mounted ingripping or displacement preventing engagement with shaft 155 generallyin the same manner as discussed hereinbefore with respect to rotor 43.Thus, rotor 453 and shaft 155 comprise rotatable assembly 451 which ismounted or otherwise arranged with stationary assembly 161 ofelectronically commutated motor 45 so as to be operable therewithgenerally in the same manner as discussed hereinbefore with respect torotatable assembly 151. Of course, it is also contemplated that magnets89, 91 in rotatable assembly 451 may be magnetized in the same manner aspreviously discussed hereinabove.

From the foregoing, it is now apparent that a novel drive for laundrymachine 247 has been presented meeting the objects set out hereinbefore,as well as others, and that changes as to the precise arrangements,shapes details and connections of the component parts of such drive maybe made by those having ordinary skill in the art without departing fromthe spirit of the invention or the scope thereof as set out in theclaims which follow.

What I claim as new and desire to secure by Letters Patent of the UnitedStates is:
 1. A drive for a laundry machine having a DC power sourceassociated therewith and means for agitating water and fabrics to belaundered thereby to wash the fabrics and for thereafter spinning thefabrics to effect centrifugal displacement of water from the fabrics,the drive comprising:an electronically commutated motor adapted to beenergized from the DC power source for driving the agitating andspinning means, said electronically commutated motor comprising astator, a multi-stage winding arrangement associated with the stator andhaving a plurality of winding stages adapted to be electronicallycommutated in a plurality of preselected sequences, and a rotatableassembly associated with said stator and arranged in selective magneticcoupling relation with said winding stages so as to be rotatably driventhereby, said rotatable assembly being rotatably driven in one directionin response to the electronic commutation of at least some of saidwinding stages in one of the preselected sequences and also beingrotatably driven in the one direction and another direction oppositethereto in response to the electronic commutation of said winding stagesin another of the preselected sequences; and means for driving theagitating and spinning means from said rotatable assembly of saidelectronically commutated motor.
 2. A drive as set forth in claim 1further comprising means for securing said electromically commutatedmotor directly onto said driving means.
 3. A drive as set forth in claim1 further comprising means for selectively effecting a driveninterconnection between said driving means and said rotatable assemblyof said electronically commutated motor.
 4. A drive as set forth inclaim 1 wherein said driving means includes means adapted for conjointrotation with said rotatable assembly of said electronically commutatedmotor.
 5. A drive as set forth in claim 1 wherein said driving means isassociated in mounting relation with said electronically commutatedmotor so as to be directly driven by said rotatable assembly thereof andincludes means adapted for conjoint rotation with said rotatableassembly.
 6. A drive as set forth in claim 5 further comprising meansassociated with at least one of said rotatable and said driving meansand selectively operable for effecting a drivdn interconnection of saidconjoint rotation means and said rotatable assembly.
 7. A drive as setforth in claim 1 wherein said rotatable assembly includes a set ofpermanent magnet material elements arranged in the selective magneticcoupling relation with said winding stages.